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Crowley Marine: serving boaters for over 40 years Crowley Marine: serving boaters for over 40 years
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HIGH ALTITUDE KIT, P/N 5005894 AND 5005895 INSTALLATION INSTRUCTIONS

Crowley Marine

APPLICATION

This kit is designed for use on 2002 and newer Johnson® 9.9 and 15 HP, 4-stroke outboards. DO NOT install on any other models.
 

SAFETY INFORMATION

For safety reasons, this kit should be installed by an authorized Evinrude®/Johnson® dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature for your engine. This instruction sheet uses the following signal words identifying important safety messages.


Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.


Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.


Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.

IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean:

ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!

Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you.

It is understood that this instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail.

DO NOT do any repairs until you have read the instructions and checked the pictures relating to the repairs.

Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.

When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.

Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.

If you use procedures or service tools that are not recommended in this instruction sheet, YOU ALONE must decide if your actions might injure people or damage the outboard.

TO THE INSTALLER: Give this sheet to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.

TO THE OWNER: Save these instructions in your owner’s kit. This sheet contains information important to the future use and maintenance of your engine.
 

DESCRIPTION

An outboard loses power at higher altitudes due to reduced air density. At 3000 ft. (915 m) above sea level and higher, additional power loss is caused by a rich fuel-to-air mixture. This causes a decrease in full throttle RPM and performance.

To regain some of the power loss at altitudes of 3000 ft. (915 m) above sea level and higher, and to improve fuel economy and running quality, install one of the following high altitude kits:

Model Kit Number Contents
9.9 HP 5005894 Pilot jet, P/N 351585
Main jet, P/N 357586
15 HP 5005895 Pilot Jet, P/N 351587
Main jet, P/N 351588

IMPORTANT: It is acceptable to replace only the pilot jet for improved idle quality and low-end performance. However, to achieve optimum performance for mid-range through wide-open throttle, replacing the main jet is also recommended.

IMPORTANT: Keep the original jets. If the outboard is returned to operation at an altitude below 3000 ft. (915 m) above sea level, reinstall the original jets in the carburetor.


 

REPLACEMENT PROCEDURE


Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.

Always work in a well ventilated area and wipe off any fuel spillage.

DO NOT smoke and make certain no open flames or ignition sources exist.

After servicing the fuel system, momentarily pressurize the fuel system and check for leaks. Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

To prevent accidental starting while servicing, disconnect battery leads from battery. Also, twist and remove all spark plug leads.

Do not attempt to run engine with any fuel system component disconnected or removed except as directed. Fuel leakage could contribute to a fire or explosion.

Always check fuel system components for signs of deterioration, cuts, cracking, or abrasion. If damaged, replace with Evinrude®/Johnson® Genuine Parts.
 

Pilot Jet

Use small flat-bladed screwdriver to remove pilot jet from carburetor and to install new pilot jet from high altitude kit.


 

Main Jet (optional)

Remove lower engine cover from port side.

Disconnect choke rod and throttle rod.

Remove two (2) mounting bolts and carburetor. Discard gasket.

Disconnect fuel hose and clear tube from carburetor.

Remove four (4) screws and float chamber.

Use small flat-bladed screwdriver to remove main jet from carburetor and to install new main jet from high altitude kit.


Do NOT reuse the carburetor gasket. The sealing capabilities will be insufficient. Air leakage will cause a lean air-to-fuel mixture, which could result in severe engine damage.

Assemble and install carburetor in reverse order. Include the following steps where appropriate:

  • Use new carburetor gasket, P/N 5033081.
     
  • Torque two (2) mounting bolts to 89 in. lbs. (10 N·m).

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